Conveyor system

ABSTRACT

A cable conveyor for transporting articles through a curved path of transport is disclosed. The conveyor has a plurality of pulley assemblies rotatably mounted on a conveyor frame. A cable tangentially contacts and is guided by each successive pulley assembly. The cable carries and transports the articles as it is pulled through a path defined by the pulley assemblies. The pulley assemblies may be spaced so that the path they define is shaped substantially the same as the shape of the conveyor frame. The conveyor may provide a spiral path of transport so that the articles may be raised or lowered. Alternatively, the conveyor may provide an arc to transport the articles from one direction of transport to another.

This is a division of co-pending application Ser. No. 847,224, filed onApr. 2, 1986, now U.S. Pat. No. 4,738,352, issued Apr. 19, 1988.

BACKGROUND OF THE INVENTION

This invention relates to conveyors for transporting articles, such ascans, within a facility, such as a factory. More particularly, thepresent invention relates to cable conveyors, and provides a means forconveying articles around corners, from one level to another, and forcooling the articles during transport.

Conveyor systems which convey articles from one level to another, thatis, lower or elevate the articles, are generally known in the art. Suchgenerally known systems include what are known in the art as double-beltelevators, side grip elevators, magnetic elevators, and cable alpinesystems.

Conveyor systems which provide a means for turning corners are alsogenerally known. Such cable conveyor systems generally use 12-inch,15-inch, or 18-inch diameter castings for this purpose.

SUMMARY OF THE INVENTION

The device of the present invention provides a conveyor system having acombination of advantages not heretofore achieved in one device. Itprovides a curved path of transport for the articles. As a lowerator andelevator, it provides for accumulation: if there is a stoppage ahead ofthe device, the articles can be accumulated so that the device need notbe shut off immediately; thus, a separate accumulation conveyor is notrequired with the present invention. In addition, the device of thepresent invention utilizes a comparatively small amount of floor spacein the facility. It can be completely manufactured outside of thefacility and can be readily installed at the facility.

As a cornering device, the present invention allows for turns with acomparatively large radius of curvature. Thus, it lends itselfparticularly well to high-speed conveying and to conveying largediameter containers.

Accordingly, the present invention provides a cable conveyor fortransporting articles through a curved path of transport. The conveyorcomprises a plurality of pulley assemblies disposed in a curved patternon a conveyor frame. A cable for carrying and transporting the articlescontacts each successive pulley assembly. The pattern of the pulleyassemblies defines the curved path of transport for the articles.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a conveyor embodying the principles of thepresent invention, with parts broken away and background omitted forclarity.

FIG. 2 is a top view of the apparatus of FIG. 1.

FIG. 3 is an enlarged sectional view of the apparatus of FIG. 1, takenalong line 3--3 of FIG. 2.

FIG. 4, is an enlarged sectional view of the apparatus of FIG. 1, takenalong line 4-4 of FIG. 2.

FIG. 5 is an exploded sectional view of a pulley assembly utilized inthe apparatus of FIG. 1 and shown in FIG. 4.

FIG. 6 is a top view of another embodiment of the present invention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT

In the accompanying drawings there is illustrated a cable conveyingdevice which embodies the principles of the present invention.Essentially intended as a conveying device for articles, such as cans,the conveyor transports the article through a curved path of transportby carrying them on a moving cable. To elevate or lower the articlesfrom one level to another, the conveyor provides a spiraling path oftransport. To turn a corner, the conveyor provides an arc.

Referring to FIGS. 1 and 2, the conveyor of the illustrated embodiment,generally designated 10, is shown positioned on the floor of a factory.The illustrated conveyor may be used as an elevator or lowerator, totransport the articles from one level to another. As an elevator, theillustrated embodiment is connected to an infeed 12 at a first lowerlevel and a discharge 14 at a second higher level. As a lowerator, thepositions of the infeed and discharge are reversed: the infeed is at thehigher level and the discharge is at the lower level.

The conveyor 10 illustrated in FIGS. 1 and 2 includes a conveyor frame16 shaped into a spiral. A plurality of pulley assemblies 18 arerotatably mounted on the conveyor frame 16 in a spiral pattern. A cable30 for carrying and transporting the articles tangentially contacts andis guided by each successive pulley assembly 18. The cable is pulledthrough the spiral path defined the pulley assemblies. In theillustrated embodiment, the pulley assemblies are disposed on theconveyor frame such that the path they define is shaped substantiallythe same as the shape of the conveyor frame 16. Thus, in thisembodiment, the shape of the conveyor frame defines the pattern of thepulley assemblies, and thereby defines the path transport of thearticles.

The embodiment illustrated in FIGS. 1 and 2 also includes a meansassociated with the conveyor frame for maintaining the articles on theconveyor and a means associated with the conveyor frame for preventinginterference between the articles and the pulley assemblies.

As shown in FIGS. 1 and 2, the conveyor frame 16 is supported on avertically-extending main frame 32. The main frame 32 is generallysquare in cross-section and is supported by support means. This supportmeans includes base members 34 which support the main frame on the floorof the facility. This support means also includes braces 36 at the topof the main frame 32, to brace the main frame against the ceiling of thefacility.

As shown in FIG. 2, the main frame 32 is encircled by the conveyor frame16. The main frame 32 carries a plurality of radially-extending supportarms 38 which serves to support the spiraling conveyor frame 16. Thesupport arms 38 are staggered at 90° intervals around the main frame 32,and each support arm 38 is disposed at a successively higher level.

The illustrated support arms 38 on one conveyor are all of the samelength, and their lengths may be for example, 24 inches, 30 inches, or36 inches. Although the invention is not limited to these lengths, withsupport arms of any of these lengths, the conveyor 10 takes up arelatively small amount of floor space in the facility.

The illustrated support arms 38 are hollow metal tubes, generally squarein cross-section. They may be secured to the main frame 32 by anysuitable means; for example, they may be welded to mounting sleeveswhich slip onto the bolt to the main frame.

To secure the illustrated support arms 18 to the conveyor frame 16, eachsupport arm includes an end cap 40, having a threaded bore so that theconveyor frame may be bolted to each support arm.

The illustrated conveyor frame 16 is formed of an elongated piece ofaluminum, curved into a spiral. The entire conveyor frame need not beformed of one piece of aluminum; several pieces may be connected to formthe spiraling frame. The upward slope of the spiral depends upon thearticles being transported, the speed of transport, and the application.An upward slope of from about 3/8 inch to 11/4 inches per foot may beused successfully in the illustrated embodiment.

The illustrated conveyor frame 16 is generally L-shaped incross-section. One face 50 is generally vertical, and has a plurality ofbores so that the conveyor frame may be bolted to the end caps 40 of thesupport arms 38.

A second face 52 of the conveyor frame 16 has two sets of holes. In oneset, the holes are spaced approximately 6 inches apart along the lengthof the frame; these holes are provided for mounting the pulleyassemblies 18 on the conveyor frame 16. A second set of holes, each holebeing deposed at 90° intervals, is provided for mounting a group of siderail saddle assemblies 54 onto the frame 16.

In the illustrated embodiment, the pulley assemblies 18 are disposed ina spiraling pattern around the conveyor frame 16, and the cable 30 isdisposed around the outside of each pulley assembly. The pulleyassemblies define a spiral path around the curve of the conveyor frame.They tangentially contact and guide the cable so that as the cable ispulled, it follows the spiral path defined by the pattern of the pulleyassemblies, a path which is shaped substantially the same as the shapeof the conveyor frame.

The cable 30 is generally circular in cross-section. In the illustratedembodiment, a 3/8 inch diameter cable is used. The cable 30 may be madeof any suitable material; the following cables have producedsatisfactory results: "Rochester" 6×19 galvanized cable with a nyloncovering; "Bethlehem" 6×19 galvanized cable; and "Volta" plastic cablewith a fiberglass core. In the illustrated embodiment, the cable 30 ispulled through the path of transport by a motor (not shown).

A pulley assembly 18 is illustrated in FIG. 4. In the illustratedembodiment it includes a cable guide sheave 56 rotatably mounted on theconveyor frame 16. The sheave 56 is made of molded plastic acetal. Itincludes a cylindrical base 58 and an annular flange 60. The annularflange 60 is disposed around the central vertical axis of the sheave 56.The flange 60 defines a concave arcuate surface, integral with the topsurface of the cylindrical base 58. The top surface of the cylindricalbase 58 slopes slightly upwardly, at an angle of about 4°-5°, from theperimeter of the base, to meet the concave arcuate surface of the flange60.

The cable 30 rides upon the top surface of the cylindrical base 58,against the concave arcuate surface of the flange 60. The concavearcuate surface's curvature is adapted to mate with the curvature of thecable 30, to maintain the cable in position against the sheave, whileleaving the top of the cable exposed above the sheave. In theillustration embodiment, the arcuate surface defines an arc of about113°; with a 3/8 inch diameter cable, about 0.060 inches to 0.090 inchesof cable is exposed above the sheave. Thus, the moving cable, intension, is maintained in position against each successive pulleyassembly, while carrying the articles above the pulley assemblies.

As shown in FIG. 5, the pulley assembly's cable guide sheave 56 has acentral bore 70 with an annular shoulder 72. The shoulder 72 iscontacted by the outer race of an upper ball bearing 74. The annularinner race of this bearing 74 is disposed around a bolt 76. The annularinner race of a sealed lower ball bearing 78 is also disposed around thebolt 76, and the lower ball bearing 78 is disposed against the upperball bearing 74. An annular thrust retaining ring 80 bears against thelower bearing 78 and is pressed into a recess 82 in the sheave 56. Anannular spacer 84 is disposed between the sheave 56 and the face 52 ofthe conveyor frame 16. The bolt 76 extends through the cable guidesheave 56, upper ball bearing 76, lower ball bearing 78, thrustretaining ring 80, annular spacer 84, and face 52 of the conveyor frame16. An end cap 86 is snap fit onto the sheave to cover the head of thebolt 76. Thus, the pulley assemblies are bolted to the conveyor frame16. They rotate freely, without interference from the conveyor frame,about essentially vertical axes.

To maintain the articles on the cable 30 and to prevent interferencebetween the articles and the pulley assemblies 18, the illustratedembodiment utilizes a plurality of side rail saddle assemblies 54 andside rails 90. As shown in FIGS. 1 and 2, the saddle assembles 54 aredisposed at 90° intervals along the conveyor frame 16, proximate to thesupport arms 38.

As shown in FIG. 3, each saddle assembly 54 includes a saddle crosssupport 92 and two opposing saddle uprights 94 bolted to the crosssupport. The cross support may be slotted so that the distance betweenthe uprights 94 can be varied to accommodate articles of differentsizes. Each upright 94 is bolted to a pair of side rails 90. The siderails 90 are curved into a spiral shape, substantially the same as thespiral shape of the conveyor frame 16. The side rails 90 may be made ofa plastic-covered 3/4 inch half-round of anodized aluminum.

An inclined saddle locator 96 is disposed between the cross support 92and the face 52 of the conveyor frame, and the saddle assembly is boltedto the conveyor frame through the locator. The saddle locator 96 servesto incline the saddle assembly 54 and side rails 90 downwardly towardthe periphery of the conveyor. In the illustrated embodiment, thelocator 96 tilts the assembly 54 and side rails about 31/2° fromvertical. Inclines of from about 2° ot 4° from the vertical shouldproduce satisfactory results.

Thus, the pulley assemblies provide a means for guiding the cablethrough a path of transport shaped substantially the same as the shapeof the conveyor frame. The cable 30 runs between the opposing uprights94 and above the cross support 92. Thus, the articles 97 are carriedbetween opposing side rails throughout and are tilted away from thepulley assemblies throughout their transport.

The illustrated embodiment may be almost completely manufactured outsideof the facility where it is to be used. It may easily be installed atthe facility by connecting the conveyor to infeed and dischargeconveyors. The infeed conveyor 12 should be pitched at about the sameangle as the spiral. Once installed, the illustated embodiment takes upa relatively small amount of floor space in the facility.

In operation, the articles are carried by the cable and transportedaround the spiral path defined by the pulley assemblies and the conveyorframe. The side rails maintain the articles on the cable, and theincline of the saddle assemblies and side rails tilts the articles sothat there is no interference between the articles and the pulleyassemblies. Because of the comparatively large radius of curvature ofthe conveyor frame, the illustrated embodiment lends itself well tohigh-speed conveying and to conveying large articles. And because thearticles are transported through frictional contact with the cable,articles may be accumulated on the running cable if there is a stoppageahead of the conveyor, without shutting down the conveyor.

In addition to serving as a lowerator or elevator, the invention may beuseful where a cooling step is needed in a manufacturing process. Forexample, two spirals may be combined to first lower and then elevate thearticles.

In addition, the present invention is useful as a cornering device, totransport the articles from one direction of transport to another. Asillustrated in FIG. 6, a conveyor frame 100 may be curved into an arc ofa comparatively large radius of curvature. A plurality of pulleyassemblies 102 are rotatably mounted on the conveyor frame 100, with acable 104 tangentially contacting each successive pulley assembly. Thepulley assemblies are spaced on the conveyor frame to define a curvedpath, shaped substantially the same as the arc of the conveyor frame.Although not shown in FIG. 6, the side rails 90 and side rail saddleassemblies 54 described above may also be used in this embodiment tomaintain the articles on the conveyor and to prevent interference withthe pulley assemblies. With the large radius of curvature available,this embodiment also lends itself well to high-speed conveying and totransporting large articles.

Although the invention has been described with respect to the twoillustrated embodiments, the invention is not limited to theseembodiments. Additional modifications and/or additions may be includedby those skilled in the art without departing from the scope of theinvention as defined by the claims.

I claim:
 1. The A pulley assembly for use in a cable conveyor system,the pulley assembly being adapted to be rotatably mounted upon aconveyor frame, the pulley assembly comprising:a cable guide sheaveincluding:a cylindrical base having a top surface; and an annular flangedefining a concave arcuate surface integral with the top surface of thecylindrical base, wherein the cable rides against the concave arcuatesurface of the annular flange and the flange is adapted to maintain theposition of the cable against the sheave while leaving a portion of thetop of the cable exposed above the sheave; and a central bore extendingfully through the sheave and having an annular shoulder therein, theshoulder and the bore being disposed around the central vertical axis ofthe sheave; a bolt extending through the central bore of the sheave forbolting the pulley assembly to the conveyor frame; a pair of bearings ina pre-assembled bearing assembly, including an upper ball bearing havingan outer race disposed against the annular shoulder in the central boreof the sheave and an inner race disposed around the bolt, and a lowerball bearing having inner and outer races disposed against the inner andouter races, respectively, of the upper ball bearing in the sheave'scentral bore, the lower bearing's inner race being disposed around thebolt, and an annular thrust retaining ring disposed against the lowerball bearing, the thrust retaining ring being pressed into a recessedarea of the sheave to hold the bearings in the central bore prior toplacement of the bolt through said bore; and an annular spacer disposedbetween the thrust retaining ring and the conveyor frame to allow thepulley assembly to rotate freely above the conveyor frame.